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Originally posted by decodeddiesel
 You've got to be kidding me JayDee...that is exactly, EXACTLY the block I was designing on paper over here during my down time. I bet the dimensions of the internals are somewhat different but the concept is EXACTLY THE SAME!!!! God damn thats crazy! I was thinking of drilling the holes around the pins with a 1/8" end mill then connecting the holes to form the channels with a small, perhaps 1/16" or 1mm bit. Overall dimensions of the pins array would turn out to be 1.2" x .9". I know between jack and squat about machining Cu though so I am probably smoking crack on that, but still, that is exactly it. I was thing the barb reliefs on either side of the channels to be .9" x .6" then have base thickness in the barb reliefs and channels to be app. 2mm and overall height of the Cu piece as 6mm. Then have 1/4" NPT tapped holes in the Plexi top with a matching .9" x .6" x .15" relief over the matching reliefs in the base plate. I am rambling and probably don't make any sense....damn stumped again, so much for that design...... 
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Yeah, I used 1/8" drill bit for the main holes and a 1/16" end mill to connect the holes. The pinned one is 3/8" and drilled down 1/4" for a 1/8" base thickness. The other one with just channels wasw the same process but i used 1/4" material and drilled 3/16" and left 1/16" for the base. I will test it out and then next time I get on the mill I will finish connecting the holes to make pins and retest it to see if it helps or not. Also have a center inlet jet deal i am thinking up.
That is one thing about this hobby, the block you have in mind has probably already been done.
This block is a mixed concept block, it uses #Rotor design, White Water design, RBX design, and even some of my own thinking to boot.